Construction Plate Suitable for a Tile Support

ABSTRACT

A stacked construction plate, including a core layer, which is equipped at least on one flat side with a coating that serves as a support layer. The support layer includes at least three layers, namely a thin transition mortar layer, which is attached to the core layer, a non-woven glass fiber layer and a connection layer, which is made from compression-resistant, hardened coating mortar having a smoothed surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of German Utility Model No. 20 2010 003 760.03, filed Mar. 17, 2010.

BACKGROUND

Embodiments of the invention relates to a multi-layered construction plate, which is in particular suitable for a tile support, comprising a core layer which is equipped at least on one flat side with a coated layer that serves as a support layer.

The support layer can be equipped in the same manner on both sides. However, it is also possible that one side, in this case the reverse side, is equipped with a reinforcing layer which is made of cement mortar and in which is embedded a wide-meshed woven grid.

Construction plates are known consisting of a core layer made of moisture-resistant foamed material which are provided on both sides with a reinforcing layer made from cement mortar and a reinforcement consisting of a wide-meshed glass fiber woven grid. Similar plates are sold by the applicant as WEDI construction plates.

It has been turned out that a disadvantage with such structural plates including a floor tile is that the front side, which is to be provided with a tile or other plate material, must be smoothed and leveled first in order to ensure that a sufficiently smooth surface will be achieved. In any case, it was not possible to simply leave out the woven reinforcement without losing as a result a desirable strength of the mortar layer.

The goal is therefore to modify construction plates according to prior art as mentioned above so as to achieve a sufficient strength also on the visible side, which ion the other hand so smooth and strong that it is suitable for coating with ceramic plates, tiles and other coatings customary in floors and dry constructions without additional smoothing or leveling.

The goal is achieved with a plate, wherein

-   -   the supporting layer comprises at least three layers, namely     -   one thin transitional mortar layer, mounted on the core layer,     -   a non-woven layer of glass fibres,     -   a connection layer made of pressure-resistant, hardened coating         mortar which has a smoothed top surface.

This kind of said support layer can be also deployed on both sides of such a core layer.

BRIEF DESCRIPTION OF THE DRAWING

The present invention will be more readily understood from the detailed description of embodiments thereof made in conjunction with the accompanying drawing of which FIG. 1. is a a schematic representation of a construction plate consistent with an embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to at least one embodiment of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiment(s) is/are described below to explain the present invention by referring to the FIGURE.

Layers that are essentially suitable for core layers of this type are preferably core layers which are moisture-resistant and made from polymer foamed material and which can be selected from the group including EPS polystyrene foamed material, XPS polystyrene foamed material, or polyurethane foamed material.

The core layer on the other side can be selected as a construction material suitable for dry constructions, which, however, is not moisture resistant, for example from the group of gypsum plaster boards including the GKB, GKF, GKP and GKS types of boards, as well impregnated gypsum plaster boards of the GKBI and GKFI type.

Another technical possibility is when the core layer is made from pressed glass wool, or from pressed stone wool, or from a honeycomb board, wherein the honeycomb is manufactured for example from a plastic material or from a paper mass.

A particularly well integrated connection layer will be achieved when the coating mortar material of the connection layer is poured on in fluid form and it is then leveled out by the effect of the force of gravity so that it hardens in this form.

It is preferred when the basic material of the coating mortar of the connection layer is selected or mixed from lime mortar, gypsum mortar or cement mortar.

As an alternative, the basic material of the coating mortar of the connection layer can be selected or mixed from loam or gypsum for construction material. Under the term “loam” is understood clay which has yellow or brownish color and a more or less rich content of quartz grains or quartz powder, which can also contain lime, mica or similar impurities.

The basic material can be a hardened reaction resin which is mixed with a filler, preferably an epoxy resin which has 2 components. When a reaction resin is employed, the resistance to pressure of the connection layer can be significantly increased when compared to conventional mortar layers. The goal is to achieve a compressive strength of the connection layer, measured individually according to DIN EN 13892, of at least 25 N/mm², preferably 30-50 N/mm².

The composition of the mortar and of the reaction resin is adjusted so that the connection layer can be coated with mortar adhering to tiles or other adhesive material without smoothing or leveling after hardening. The coating capability without smoothing and leveling should be achieved also with a connection layer and basic materials which do not contain solvent, with paint coating materials and with covering layer means.

The thickness of the non-woven glass fiber layer is preferably adjusted to create a thin layer, which is to say that the non-woven glass fiber layer has a surface weight amount of 100 g/m² at the most.

The thickness of the transition mortar layer is preferably in the range from 0.1 to 2.5 mm.

The construction plate is preferably a non-woven glass fiber layer which is fully covered by the connection layer. However, one part of the area in the edge region may be excluded from this covering.

In order to simplify the handling of the construction plate, it is proposed to equip the construction plate with a reinforcement band in the area of the side edge in impacted overlapping locations of construction plates when the plates are arranged next to each other.

It is also possible to create a groove on the side edge of the construction plate running along the side edge so that a tongue is arranged along the side edge, wherein construction plates which are arranged next to each other can form a connection consisting of a groove and a tongue.

FIG. 1 indicates a schematic representation of an embodiment and it is not according to correct scale. The FIGURE shows a cross-section of a construction plate provided with layers which can be selected according to an embodiment of this invention.

A core layer 1 is made of an insulating, rigid material. In this case it is a layer that is manufactured from extruded polystyrene foam, which is covered on the reverse side (here below) with a reinforcing layer 2 made of cement mortar, and in which a wide-meshed woven grid 3 or grid structure is embedded.

On the opposite front side of the core layer 1 is arranged a coating which labeled as support layer 4. The support layer 4 comprises a transition mortar layer 5, which has a thickness of about 2.0 mm and which is made from cement mortar having the same composition as the cement mortar of the cement mortar layer 2 on the bottom side.

On the transition layer 5 is deployed a non-woven glass fiber layer 6 with a surface coating weight amount of about 50 g/m². Commercially available glass fibers can be used in this case which have the length of 2 to 20 mm and a thickness of 0.2 to 1 mm.

On the glass fiber tile layer 6 is attached a connection layer 7, which has a thickness of 1 to 5 mm and which is made of a curable cement mortar or a 2-component mixture consisting of an epoxy resin and a filler. The connection layer was originally poured on in liquid form, and it was then leveled and smoothed by the effect of the force of gravity so that it hardened in this manner. The result is a smooth and unstructured top surface area on which work can be performed without additional smoothing and leveling.

Typically, an adhesive layer 8 is applied to the connection layer 7, to which individual tiles 9 can then be glued.

Although selected embodiment(s) of the present invention has/have been shown and described, it is to be understood the present invention is not limited to the described embodiment(s). Instead, it is to be appreciated that changes may be made to the disclosed embodiment(s) without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof. 

1. A multi-layered construction plate, which is in particular suitable for a tile support, comprising: a core layer having at least on one flat side with a coated layer that serves as a support layer, wherein the support layer comprises at least 3 layers, namely a thin transition mortar layer, which is attached to the core layer, a non-woven glass fiber layer, and a connection layer, made from pressure-resistant, hardened coating layer having a smoothed surface.
 2. The construction plate according to claim 1, wherein the core layer is resistant to moisture and comprises a polymer foamed material selected from the group including EPS polystyrene foamed material, XPS polystyrene foamed material, or polyurethane foamed material.
 3. The construction plate according to claim 1, wherein the material for core layer is made of a construction material that is suitable for dry construction, but that is not resistant to moisture, selected from the group including gypsum plaster boards including the GKB, GKF, GKP and GKS type, as well impregnated gypsum plaster boards of the GKBI and GFKI type.
 4. The construction plate according to claim 1, wherein that core layer comprises pressed glass wool or pressed stone wool.
 5. The construction plate according to claim 1, wherein the core layer is a honeycomb board, and wherein the honeycomb is manufactured from plastic material or from a paper mass.
 6. A construction plate according to claim 1, further comprising a support layer on the top side and a reinforcement layer on a bottom side, which is provided with a wide-meshed woven grid or a grid structure on the bottom side.
 7. The construction plate according to claim 1, wherein a coating mortar of a connection layer is poured on in liquid form, and is later leveled out and smoothed under the effect of the force of gravity so that it hardens in this form.
 8. The construction plate according to claim 1, wherein the basic material of the coating mortar of the connection layer is selected or mixed from lime mortar, gypsum mortar or cement mortar.
 9. The construction plate according to claim 1, wherein the basic material of the coating mortar of the connection layer is selected or mixed from loam or from gypsum for construction material.
 10. The construction plate according to claim 1, wherein the basic material comprises a commercially available filler admixture, a hardened reaction resin, preferably epoxy resin having 2 components.
 11. The construction plate according to claim 1, wherein the compressive strength of the connection layer, measured individually according to the DIN EN 13892 standard, is at least 25 N/mm².
 12. The construction plate according to claim 11, wherein the compressive strength of the connection layer, measured individually according to the DIN EN 13892 standard, is between 30-50 N/mm².
 13. The construction plate according to claim', wherein the connection layer can be coated with mortar adhering to tiles or with another adhesive material without leveling and smoothing.
 14. The construction plate according to claim 1, wherein the connection layer can be coated with: basic materials that do not contain a solvent; with paint coat materials; and with covering layers means without leveling and smoothing.
 15. The construction plate according to claim 1, wherein the non-woven glass fiber layer has a surface coating weight amount of 100 g/m² at the most.
 16. The construction plate according to claim 1, wherein the thickness of the transition mortar layer is between 0.1 and 2.5 mm.
 17. The construction plate according to claim 1, wherein the non-woven glass fiber layer is fully covered by the connection layer (7).
 18. The construction plate according to claim 1, wherein the non-woven glass fiber layer is fully covered by the connection layer with the exception of at least one part in the edge region of the construction plate.
 19. The construction plate according to claim 1, wherein it is equipped with a reinforcement band in the area of the side edge in impacted overlapping locations of construction plates when the plates are arranged next to each other.
 20. The construction plate according to claim 1, wherein a groove is created on the side edge of the construction plate running along the side edge, wherein a tongue is arranged along the side edge so that construction plates which are arranged next to each other can form a connection consisting of a groove and a tongue. 